GUIDANCE

Pipe modelling for

Tulcea Pipe Spool Workshop

Doc.no. STD-771-110 | Revision: A | 10 th January 2014 | Prepared by: RG

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Guidance: Pipe modelling for Tulcea pipe spool workshop
STD-771-110 Rev. A

TABLE OF CONTENTS
1 INTRODUCTION, AUTOMATED PIPE FABRICATION ............................................................................................. 3
1.1 NEW ASPECTS FOR 3D MODELLING OF PIPES .......................................................................................................... 4
1.2 PIPE SYSTEMS FOR BENDING ............................................................................................................................... 5
2 DESIGN GUIDELINES ........................................................................................................................................... 6
2.1 DESIGNING PIPES FOR BENDING ........................................................................................................................... 6
2.2 DESIGNING PIPES FOR BENDING WITH PRE-WELDED FLANGES ...................................................................................... 7
2.3 ANATOMY OF A BENDING MACHINE ..................................................................................................................... 8
2.4 SELECTING CORRECT WALL THICKNESS ................................................................................................................... 9
2.5 S-PIPES ........................................................................................................................................................11
2.6 SINGLE ELBOWS WITH FLANGES ..........................................................................................................................12
2.7 PIPE SPOOLS WITH T-PIPE .................................................................................................................................12
3 EXAMPLES: DESIGN PIPES FOR BENDING...........................................................................................................13

Revision changes:

General: Chapter indexing

New chapter 1.2 (Pipe systems for bending)
Chapter 2.1: Modified table A
New chapter 2.2 (Designing for bending with pre-welded flanges)
Updated chapter 2.4 (Selecting correct wall thickness)

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Guidance: Pipe modelling for Tulcea pipe spool workshop
STD-771-110 Rev. A

1 INTRODUCTION, AUTOMATED PIPE SPOOL WORKSHOP

Vard Group has built a new pipe workshop in Tulcea yard for automated prefabrication of pipe spools. The
workshop has several new machines and an integrated computer system.

One of the goals is to increase the use of bending pipes instead of using commercial elbows. The two
bending machines in the workshop can handle carbon steel pipes with dimensions from DN50 to DN200
(see ch. 1.2). The bending radius is 1,5xD, which is the same building length as for commercial elbows.

The advantages with bending of pipes are primarily time saving, but also less potential leakage points
(welds) because of the reduced number of welds. For prefabrication of a pipe spool with welded elbows, a
fabrication time reduction of 90% can be achieved by bending the spool instead of conventional welding.

All carbon steel pipes between DN25 to DN350 shall be planned for going through the pipe workshop, even
if the pipe is not bent. There are saws, sandblasting, welding machines, and transport facilities etc. that also
prefab pipes will have a huge benefit of.

In the Pipe workshop there is an own computer based control system that are handling the building
information. As before, engineers are routing the pipes and making iso-drawings, but now a new file called
“IDF” will be generated automatically from the iso, and stored at the same spot as the plot files.

If a system is designed for bending with 1,5xD, and later it is decided that it shall be built with commercial
elbows (1,5xD), there is a tool in the computer system that are creating new isometrics with the correct
dimensions for prefab the pipes. Changes in Aveva model will therefore not be needed.

We will still have the bending machines with other bending radiuses (2D, 3D etc).
When starting up on a project, it shall be decided what bending machines that shall be used on the
different systems. If it’s not decided ask for it before starting modelling.

LAYOUT: TULCEA PIPE WORKSHOP

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Guidance: Pipe modelling for Tulcea pipe spool workshop
STD-771-110 Rev. A

New bending machines in the pipe workshop

In the pipe workshop we have two bending machines for bending R=1,5xD.
Schwarze Robitec CNC 100 HD: Schwarze Robitec CNC 220 HD:
This machine will handle: This machine will handle:
DN50, DN65, DN80 and DN100. DN125, DN150, and DN200.

NOTE: Since we still have available the old bending machines with other bending radiuses (R=2,0xD, 3,0xD
etc.) these machines may still be used for some systems in our projects.

1.1 NEW ASPECTS FOR 3D MODELLING OF PIPES

There are some important issues that all pipe designers have to follow (there will be exceptions):

Design the pipe for maximum utilization of the bending machines. Design rules are described in ch. 2.

Design the pipe so that single pieces of pipe can be transported on the roller conveyors. Single pipe
pieces should not be shorter than 800mm, due to the design of roller conveyors (see picture below).

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

1.2 PIPE SYSTEMS FOR BENDING

The CNC100HD and CNC220HD bending machines in the pipe workshop are designed to bend carbon steel
pipes of P235GH quality, with pipe sizes from DN50 to DN200. See table below.

Available mandrel tools

Bending machine Nominal pipe diameter Available tools (mandrels) for pipe wall thickness
CNC-100 DN 50 4,5 6,3
CNC-100 DN 65 4,5 6,3
CNC-100 DN 80 4,5 6,3
CNC-100 DN 100 4,5 6,3
CNC-220 DN 125 4,5 6,3
CNC-220 DN 150 4,5 6,3 8,8
CNC-220 DN 200 6,3 8,8

Pipe systems for bending in the automated Pipe Spool Workshop:

SFI System Note
326 Bulk handling system Only pipes for compressed air supply
351 FO cargo
352 FW cargo
357 Mud cargo
358 Brine cargo
359 Base oil cargo
382 Tank cleaning
571-101 Chilled water
571-102 HVAC
577 Central heating system
581 Sanitary supply / FW transfer
582 Sanitary discharge system
641 Steam system
701 Fuel oil transfer system
703 Fuel oil supply system
711 Lub oil system
722 FW cooling system
731 Compressed air system / starting air
801 Water ballast / drillwater system
803 Bilge system
804 Drain system (internal and external) (unless long radius (2,0xD) bends are used)
813 Fire line system
814 Fi-Fi system
821 Tank vent system & FO overflow
822 Sounding pipes (unless long radius ( 2,0xD) bends are used)
831 Hydraulic oil (low pressure)

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2 DESIGN GUIDELINES
2.1 DESIGNING PIPES FOR BENDING
Table A: Minimum straight lengths
Pipe nominal Pipe outside Minimum length Minimum length Minimum length
diameter diameter [mm] (A) [mm] (B) [mm] last end (C) [mm]
DN 50 60.3 135 232 400
DN 65 76.1 160 213 400
DN 80 88.9 175 193 400
DN 100 114.3 230 230 400
DN 125 139.7 300 446 500
DN 150 168.3 350 397 500
DN 200 219.1 540 540 500

Lengths A and B are needed because the bending machine is clamping the pipe in this area during bending.
Length B is needed to avoid collisions between the bent pipe and the machine itself (in many situations the
length of (B) still can be reduced to value of (A); the fabrication-control application in AVEVA will check for
collisions). Length C is last end of the pipe, and is longer because of the pressure die length (see ch. 2.3).

Essential segments of a bent pipe How to design a pipe with clamping length
In first end and between elbows

Aim at, as a minimum, using the specified lengths for A, B and C as stated above.
If a spool is modelled for bending, with shorter lengths for A, B or C than required, the pipe will first be bent
with sufficient lengths acc. to requirements. Afterwards the pipe will be cut to the correct lengths acc. to
iso-drawing. This solution is not optimal because the prefab time and thus the production cost will increase.

Selecting bending machine in AVEVA:

When modelling pipes for bending, you need to select one of the following bending machines in AVEVA:
SCHWARZE_ROBITEC_CNC100 FACTORY (For sizes DN50, 65, 80, 100)
SCHWARZE_ROBITEC_CNC220 FACTORY (For sizes DN125, 150, 200)

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2.2 DESIGNING PIPES FOR BENDING WITH PRE-WELDED FLANGES

In the pipe workshop it is possible to bend pipes after flanges are welded on (by an automatic welding
machine).For the bending machine to handle spools with flanges, longer parts of straight pipe is needed:

Table B: Minimum straight lengths for flanged pipes

Pipe nominal Pipe outside Minimum length Minimum length Minimum length
diameter diameter [mm] first end (D) [mm] (E) [mm] last end (F) [mm]
DN 50 60.3 170 284 515
DN 65 76.1 191 267 481
DN 80 88.9 247 249 447
DN 100 114.3 249 230 399
DN 125 139.7 356 501 1091
DN 150 168.3 543 455 1098
DN 200 219.1 547 540 1097

Essential segments of a pipe If the second segment (E) is too short,

bent with pre-welded flanges the pipe may clash with the bending machine.

Selecting bending machine in AVEVA:

When modelling flanged pipes for bending, you need to select one of the following bending machines in
AVEVA (different names than in ch. 2.1 because of different parameters for clash with the machine):
SCHWARZE_ROBITEC_CNC100 FACTORY FLANGE (For sizes DN50, 65, 80, 100)
SCHWARZE_ROBITEC_CNC220 FACTORY FLANGE (For sizes DN125, 150, 200)

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2.3 ANATOMY OF A BENDING MACHINE

The minimum clamping length is important because of the straight pipe needed for clamp die (see below).
This length is needed in the first end of a pipe and between two elbows on a bent pipe.

The pressure die supports the pipe end through the bending operation, and therefore a certain minimum
length is required for the last end.

The collet (not shown on the illustration) is the device behind the pressure die which, by firmly clamping
the pipe end, is holding, rotating, and forward / backwards transporting the pipe.

Vital components of a bending machine head

Bending Ø219,1x8,8mm pipe

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2.4 SELECTING CORRECT WALL THICKNESS

Reduction in wall thickness

When bending pipes with R=1,5xD, there will be a wall thickness reduction of approximately 25%. This
reduction is for all bend angles of 20 degrees and above.
The wall thickness reduction will appear on the outside part of the bend (indicated with red colour)
(For the inner part of the bend the wall thickness will actually increase due to compression).

Wall thickness reduction outside the bend Section cut of a bent pipe

To compensate for this; an increased wall thickness is required for the following piping systems:
Seawater systems: High pressure (>16 bar) systems:
- water ballast - starting air
- fire line - brine cargo
- Fi-fi pipes DN200 - mud cargo

Important: The required minimum wall thickness for bending will vary from system to system.
The correct wall thickness for each system is found in Vard Pipe Standard (see example next page).

Thick walled pipes in tanks can also be bent, as long as the correct mandrel tool is available (see available
tool sizes in ch. 1.2).

The minimum wall thicknesses when bending with R=1,5xD are calculated acc. to STD-104-050 “Vard Cold
bending of steel pipes”. The calculations are DNV approved and in accordance with DNV rules for cold
bending (Pt. 4, Ch. 6, Sec. 7A and 8C).

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

Example: Designing DN150 water ballast pipe for bending 1,5xD

1: Check in the project if your pipe system shall be produced in Tulcea Pipe Spool Workshop (and bent with
radius R=1,5xD)

2: Find correct wall thickness in VARD Pipe Standard.

For Water Ballast, SFI 801, DN150 --> 6,3mm must be used for bending

3: Both the bend and pipe must have same wall thickness.

Vard Pipe Standard is available on Vard Intranet under “Technical Standards / Piping”.
https://inside.vard.com/ba/Offshore/TechnicalStandards/Piping/Forms/AllItems.aspx

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2.5 S-PIPES

Sometimes you need to make an S-pipe with two close bends:

To be able to bend this spool, the operator of the machine need to have enough straight pipe for the clamp
distance between the bends. After bending he will cut out the excess straight pipe and weld the pieces
together as shown above.

If possible, try to have a minimum distance between the bends equal to the pipe outside diameter. This is
to ensure that the pipe is fully circular where it is welded (the pipe is oval/flattened at the end of the bend).

If you need even shorter distance than shown above, use commercial elbows.

Reducing bending angle to get good grip length (clamp length)

Another option, if you have the space, is to reduce the angle of the two bends, see illustration below.

Decrease the angle of both bends until you have the sufficient grip length according to table A.
You can use any bend angle between 0 and 90 .

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

2.6 SINGLE ELBOWS WITH FLANGES

In situations where two flanges must be directly attached to one single elbow, it is best to use a commercial
elbow (not bend from the bending machine).

2.7 PIPE SPOOLS WITH T-PIPE

In the example below, a welded T-pipe is used on the spool. When producing this spool, the straight pipe
will first be bent in the bending machine. Then it will be cut and the T-pipe will be welded in its position.

NOTE: To avoid branch error, the T-pipe must have the same wall thickness as the pipe.

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

3 EXAMPLES: DESIGN PIPES FOR BENDING

When routing pipes for bending, try always to have enough straight pipe from the bends (ref. chapter 2.1
and 2.2).

DN 80 pipe, straight length of first pipe end:

140

Not OK, too short distance between

bend and coupling (need minimum
clamp length 175mm acc. to table A).

In this case, pipe end needs to be cut

after bending (increased production
time).

250

OK, enough distance to finalize

the bend with the clamping
length.

In this case, the pipe spool can be

sent directly from bending to
Victaulic grooving machine.

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Guidance: Modelling pipes for Tulcea pipe workshop
STD-771-110 Rev. A

Other straight pipe lengths:

This length is too

short, so it has to be
cut after bending

Good
length

Too short This arrangement is

possible, but the
workshop will have
Good to cut and weld the
pipe after bending
(see. ch. 2.5).

Good

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